Unitary supplementary packaging systems

ABSTRACT

The present invention is directed to new premium retail disposable packaging systems. In particular, the packaging systems of the present invention offer a secondary/supplementary compartment with opening facial angles positioned through an inversion hinge at a supplementary pairing angle to one of the primary compartment containment side-walls. Such designed packaging systems offer a premium appearance that is more appealing to the consumer by separating additional components (such as utensils or condiments), and orienting the supplementary compartment behind/underneath the product for display, as well as reducing the potential for contamination of a product with potentially non-sanitized additional components. In specific embodiments, this packaging system may be positioned in a standing orientation to further increase the premium nature of the product displayed.

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 62/883,111, filed on Aug. 5, 2019; the entirety of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

Products may be packaged for retail sale in a wide array of systems. For example, products may be packaged in boxes, in cartons, on hanger systems, in plastic shrink-wrap, or even in containers uniquely configured to the product specification. However, certain products lend themselves for display on retail shelves. For products to be displayed on retail shelves, it is particularly advantageous for that product packaging to display clearly the contents, and in certain cases to facilitate a self-standing arrangement of the products.

Consumers of products are strongly influenced by the impression a retail container provides as it displays the product, particularly when faced with competing products. Given this, retailers have made numerous efforts to compete in the marketplace by preparing packaging that is designed to highlight the product in the best and fullest way possible for consumer viewing, and even preparing self-standing packaging that presents consumer viewing angles that display the product in a way that attracts the attention of the consumer. However, in order to achieve favorable consumer viewing angles, and given the near vertical side walls, specialized shelving is commonly employed or alternative means of displaying these products is engaged, for example, such as being stacked, being placed on hangers, or other special accommodations made to display the containers.

In conflict with these objectives, disposable containers in retail stores often package food products along with additional components for use with the food product located in the storage compartment, including utensils or condiments, which obscure the view of the product itself and reduce the favorable impression to the consumer. Furthermore, these additional components are very often not sanitized prior to co-packaging; where such additional components often sit on the food in the packaging, and thus making the food suspect, or viewed as such by the consumer.

Unlike the potentially more complex long-term reusable (or “non-disposable”) container products, disposable containers are under significant manufacturing restrictions with respect to the designs that are possible, i.e., based on the thermoforming processes used to produce them. Such restrictions limit the complexity of these disposable containers, yielding, for the most part, only single compartments with the option for segmented trays suitable for dividing the separate foods and utensils/condiments. Such configurations clearly reduce the premium look and feel of the container, and therefore the product contained therein.

As such, there is a need for new premium retail disposable containers and packaging systems, which address these noted concerns and advance a more premium display of the products contained therein. Further, there is also a need for such containers and packaging systems to offer self-standing orientations to further increase the premium nature of the product displayed.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to new premium retail disposable packaging systems. In particular, the packaging systems of the present invention offer a secondary/supplementary compartment with opening facial angles positioned through an inversion hinge at a supplementary pairing angle to one of the primary compartment containment side-walls. Such designed packaging systems offer a premium appearance that is more appealing to the consumer by separating additional components (such as utensils or condiments), and orienting the supplementary compartment behind/underneath the product for display, as well as reducing the potential for contamination of a product with potentially non-sanitized additional components. In specific embodiments, this packaging system may be positioned in a standing orientation to further increase the premium nature of the product displayed.

As such, one aspect of the invention provides a unitary supplementary packaging (USP) system comprising a base portion forming the primary storage compartment wherein the base portion is defined by a bottom storage tray in combination with at least three containment side-walls enclosing a volume of storage space to form said primary storage compartment; a cover portion designed to be mated to the rim of the base portion for opening and closing access into the primary storage compartment; and a supplementary compartment linked to an extension flange of the base portion through an inversion support hinge that positions the opening facial angle of the supplementary compartment adjacent to one containment side-wall of the base portion, wherein the angle of said one containment side-wall of the base portion is structured to be a supplementary pairing angle of the opening facial angle of the supplementary compartment.

BRIEF DESCRIPTION OF THE FIGURES

Advantages of the present apparatus will be apparent from the following detailed description, which description should be considered in combination with the accompanying figures, which are not intended to limit the scope of the invention in any way.

FIG. 1 is a top down perspective view of certain embodiments of the unitary supplementary packaging (USP) systems of the present invention depicted with the cover portion in open position and linked to the base portion through a wedged fracture tab (WFT), and further depicted with a supplementary compartment in the open position linked to the base portion through an inversion support hinge.

FIG. 2 is a side profile view of certain embodiments of the unitary supplementary packaging (USP) systems of the present invention depicted in FIG. 1.

FIG. 3 is a top down perspective view of certain embodiments of the unitary supplementary packaging (USP) systems of the present invention depicted with indications of the frangible and non-frangible score lines.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to new premium retail disposable packaging systems. The unitary packaging systems of the present invention offer two compartments connected to make one single package system in a unique arrangement that provides a more premium appearance to the product in the primary compartment by orienting the separate supplementary compartment behind/underneath the product for display, as well as reducing the potential for contamination of the product with potentially non-sanitized additional components. In particular, the packaging systems of the present invention offer a secondary/supplementary compartment with opening facial angles positioned through an inversion hinge at a supplementary pairing angle to one of the primary compartment containment side-walls. Such designed packaging systems offer a premium appearance that is more appealing to the consumer by moving additional components (such as utensils or condiments) from the position of being within the same compartment to a separate and more sanitary location in the supplementary compartment. In specific embodiments, this packaging system may be positioned in a standing orientation to further increase the premium nature of the product displayed.

The present invention, including packaging systems and methods will be described with reference to the following definitions that, for convenience, are set forth below. Unless otherwise specified, the below terms used herein are defined as follows:

1. Definitions

As used herein, the term “a,” “an,” “the” and similar terms used in the context of the present invention (especially in the context of the claims) are to be construed to cover both the singular and plural unless otherwise indicated herein or clearly contradicted by the context.

The language “dosed position” describes the characterization of the container status when the cover portion and the base portion of the container are reversibly interlocked. For example, in certain embodiments, this would occur when the peripheral locking flange assembly and the upper peripheral sealing edge of the base are reversibly interlocked. This language is distinguished from the language “facially closed,” described herein.

The language “consumer favorable display angle” is used herein to describe the angle of display to the consumer of the products contained in the primary storage compartment upon placement of the container in a standing orientation. Certain angles of display are more favorable for consumer viewing and offer a greater showcase of the products contained therein, e.g., a display angle from 10 to 20 degrees from vertical. For clarity, the display angles are measured from a 90 degree vertically positioned cover (i.e., that intersects perpendicularly with a horizontal surface).

The term “facially” or “facial” is used to describe the two-dimensional surface (or geometrical plane) that characterizes the opening of the supplementary compartment. Such geometrical plane may be described by an angle (with respect to a wall of the supplementary compartment) and thus defines the opening facial angle. Further, when the inversion support hinge positions the opening facial angle of the supplementary compartment adjacent to one containment side-wall of the base portion, the supplementary compartment is described as “facially closed,” while all other orientations are considered “facially open.”

The term “flange” is art-recognized and is used herein to describe a projecting flat rim or collar on an object, serving to strengthen an object's position on a structure upon which it rests, e.g., a lip or a rail structure. In certain embodiments of the containers of the present invention, the flange is part of a “peripheral locking flange assembly” which serves to contribute to the physical locking in place of the cover by interlocking with the upper peripheral sealing edge of the base, i.e., the flange is the outer edge of this assembly. In particular embodiments of the present invention, the flange comprises a truncated recessed flange (TRF).

The term “fracture” is used herein to describe the act of tearing of a frangible score line or perforation. Moreover, the language “full fracture” describes the complete tearing away of the two sides of a frangible score line or perforation.

The term “frangible” is used herein to describe the characteristic of a material that is scored with perforated score lines that is intended to tear easily and cleanly at the point or line(s) made frangible. For example, a score line or perforation may be made frangible by the relative depth of the score, length, and/or number of the perforation designed or engineered to tear easily and cleanly. Alternatively, such score lines or perforations may be designed to be non-frangible by selecting a relative depth of the score and/or length of the perforation so as to not tear easily and/or cleanly; with an intention to act as something other than a tear point/line, e.g., for folding in, for example, a flexible hinge. For clarity, non-frangible score lines or perforations, given enough force or effort, may be torn, however are not torn easily (e.g., without a tool), nor cleanly torn (e.g., without producing distortion effects on the edges), in accordance with industry accepted standards of frangible score lines or perforations.

The language “hinge width” is used herein to describe the distance between the base extension flange and the supplementary compartment.

The term “inversion,” as used in the language “inversion support hinge” is used herein to describe the changing the direction by roughly 180 degrees, e.g., to essentially cause to reverse the direction. For example, the inversion support hinge describes a support hinge that changes direction by about 180 degrees.

The term “imprinting” is art-recognized and is used herein to describe the act of either embossing or debossing a graphic image, e.g., textual, pictorial, or a combination of both. The product of imprinting is an imprint, which is either an embossed or debossed product. Embossing and debossing are techniques used to imprint impressed or depressed images onto material. Embossing produces a raised design, e.g., text or graphic image, which is pressed into material from underneath. Embossing utilizes two dies (a male and female die). In particular embodiments, the imprinting may be printed upon, or the material may be printed upon before imprinting occurs.

The term “mated” or “mating” is used herein to describe the act of two items, which have parts that can interlock, engaging to fit together. In the present invention, the cover and base portions are designed to mate in order to achieve suitable interlocking.

The language “outside angle” is used herein to describe the angle of the triangular prism shaped supplementary compartment that is opposite the opening facial angle and is positioned as the new outside wall when the supplementary compartment is in the dosed position.

The term “substantially” is used herein in reference to the degree or extent of the term which it modifies, and that such extent is near but not exactly 100%, and industry accepted standards will assist in defining the quantitative aspects of how “near” 100% is defined. For example, as used in the term “substantially eliminate access,” the term “substantially” would indicate that most access by a typical consumer utilizing expected access techniques would be eliminated.

The term “system” is used herein synonymously with “container systems” or “packaging systems” of the present invention. The term “system” is used herein to describe containers with multiple and separate compartments (in contrast to dividers in a singular tray.

The terms “tamper” or “tampering” are art-recognized and are used herein to describe the altering or adulteration (e.g., unintentional or deliberate) of a product, a package, package system, or container.

The language “tamper evident” is art-recognized and is used herein to describe a container or feature of the container that makes tampering with the container easily detected, e.g., through visual inspection. In certain embodiments, in that such tamper evident features are designed to present difficulty in accessing the contents of the container (i.e., without being detected), the unitary supplementary packaging (USP) systems may be considered tamper resistant.

The term “tray” is used herein to describe the bottom of the primary compartment.

The language “truncated recessed flange (TRF) assembly” as used herein, describes the flange located on the outer edge of the peripheral locking flange assembly on the cover portion of certain containers of the present invention comprising a truncated or shortened structure/appearance. Such language is used in contrast to the art-recognized outwardly extending peripheral flange located on the periphery of a cover characterized by its length, which extends outwardly over the lip presented by the base (e.g., and guarded from access by an upwardly projecting bead); as opposed to the flange described herein, which is characterized by having substantially no extending overlap, e.g., no extending overlap, beyond the lip presented by the base. In certain embodiments, this TRF substantially eliminates, e.g., eliminates, access to the peripheral locking flange assembly, to prevent opening of the container without fracturing the WFT.

The language “standing orientation” is used herein to describe the orientation of the display container positioned vertically on a side-wall, e.g., on the new outside wall when the supplementary compartment is in the dosed position as described herein. The container may be positioned in the standing orientation and display the products to the consumer at an angle, e.g., a consumer favorable display angle.

II. Unitary Supplementary Packaging (USP) Systems of the Invention

The present invention is directed to unitary supplementary packaging (USP) systems, i.e., container systems. Such systems are useful as premium retail disposable packaging systems and comprise a secondary supplementary compartment with opening facial angles positioned through an inversion hinge at a supplementary pairing angle to one of the primary compartment containment side-walls. Such designed packaging systems offer a premium appearance that is more appealing to the consumer by separating additional components, and orienting the supplementary compartment behind/underneath the product for display, as well as reducing the potential for contamination of a product with potentially non-sanitized additional components. In specific embodiments, this packaging system may be positioned in a standing orientation to further increase the premium nature of the product displayed. In this way, the appearance of the display container is enhanced with a greater viewable container to construct ratio, and therefore a more premium look and feel.

As such, in one embodiment, the present invention provides a unitary supplementary packaging (USP) system comprising

-   -   a base portion forming the primary storage compartment wherein         the base portion is defined by a bottom storage tray in         combination with at least three containment side-walls (e.g., 4         sides) enclosing a volume of storage space to form said primary         storage compartment;     -   a cover portion designed to be mated to the rim of the base         portion for opening and closing access into the primary storage         compartment; and     -   a supplementary compartment linked to an extension flange of the         base portion through an inversion support hinge that positions         the opening facial angle of the supplementary compartment         adjacent to one containment side-wall of the base portion,         wherein the angle of said one containment side-wall of the base         portion is structured to be a supplementary pairing angle of the         opening facial angle of the supplementary compartment.

In certain embodiments of the present invention, the inversion support hinge is connected to the extension flange of the base through a flexible non-frangible score line.

In certain embodiments of the present invention, the inversion support hinge is connected to the flange of the supplementary compartment through a flexible non-frangible score line.

In certain embodiments of the present invention, the width of the inversion support hinge is about the same as the base extension flange length. The inversion support hinge, when in the inversion position, runs parallel to the flange.

In certain embodiments of the present invention, the inversion support hinge comprises a raised ridge (e.g., to add structural rigidity).

In certain embodiments of the present invention, the system may be positioned in a standing orientation on the outside wall and rim of the base portion creating a consumer favorable display angle of the primary storage compartment. In certain embodiments of the invention, the consumer favorable display angle ranges from about 5 to 25 degrees from vertical. In certain embodiments of the invention, the consumer favorable display angle is about 15 degrees from vertical.

In certain embodiments, the packaging system may achieve the consumer favorable display angle utilizing product fill tip-control. In this respect, at certain depth to height ratios, the product weight is taken into account to prevent tipping of the container in the standing orientation.

In certain embodiments of the present invention, the unitary supplementary packaging (USP) system further comprises a hinge connecting the cover portion to the base portion. In certain embodiments, the hinge is positioned opposite the inversion support hinge.

In certain embodiments of the present invention, the unitary supplementary packaging (USP) system further comprises a hinge connecting the cover portion to the base portion, wherein the hinge comprises a tamper evident linkage structure. In certain embodiments, the tamper evident linkage structure comprises a wedged fracture tab (WFT), e.g., with an integrated non-frangible hinge, wherein the WFT is configured to produce access flaps upon full fracture and removal of the tab from the cover and base portions.

In certain embodiments of the present invention, the unitary supplementary packaging (USP) system further comprises an arced edge lock.

The unitary supplementary packaging (USP) systems of the present invention, are not limited by size or shape, i.e., the packaging systems may be any size or shape. In certain embodiments, the shape of the unitary supplementary packaging (USP) systems of the present invention may be selected from the group consisting of square, rectangle, round, elliptical, triangular, pentagon, hexagon, octagon, oval, quatrefoil, and curvilinear triangle; wherein the reference to shape describes the two dimensional shape of the primary compartment as viewed from the top of the package system, looking downwards, In certain embodiments, these shapes may be formed by arced lines (as compared with straight lines). In particular embodiments, the lower perimeter of the base portion is formed with straight lines, and the upper perimeter of the base portion (e.g., where the cover portion is placed to interlock with the base portion) is formed with arced lines. In addition, the shapes may contain arced vertices, which creates an arced edge lock at the corners of the shaped container structure, and which improves leak resistance.

In a particular embodiment of the invention, the unitary supplementary packaging (USP) system comprises a base portion opening with a rectangle shape, e.g., formed with arced lines, In certain embodiments, the three-dimensional shape of the base portion of this packaging system is an asymmetric truncated rectangular pyramid (see, for example, FIGS. 1 and 2), but are not otherwise limited by size or shape.

In certain embodiments of the present invention, the volume capacity of the primary compartment is selected from 2 US fluid ounces to 64 US fluid ounces (e.g., wherein the volume size measurements are based on an industry standard “fill line” in fluid ounces). In certain specific embodiments, the dimensions of the primary compartment range from 0.5 inches by 1.5 inches by 1.5 inches to 6.0 inches by 14.0 inches by 14.0 inches, In certain specific embodiments, the dimensions of the primary storage compartment range from length 4″-15″ by width 4″-15″ by depth 1″-5″.

In certain embodiments of the present invention, the unitary supplementary packaging (USP) system may comprise an imprint in any location or component of the container such that it does not affect the ability of the container to perform its intended function. In particular embodiments, the imprinting may be printed upon, or the material may be printed upon before imprinting occurs.

In certain embodiments of the present invention, the unitary supplementary packaging (USP) systems further comprises printed graphics, e.g., distortion control printed graphics. In particular embodiments, the printed graphics comprise 2 or more colors. In particular embodiments, the printed graphics comprise 3 or more colors. In certain embodiments, the printing may be on the upper surface (product facing) of the packaging system, the lower surface (underside that faces away from the product) of the packaging system, or a combination of both.

In certain embodiments of the present invention, the distortion control printed graphics serve as an advanced tamper alert comprising a multi-color indication of tampering, wherein the wedged fracture tab (WFT) comprises printing of a different color than the container regions adjacent to the WFT, e.g., at least the cover portion access flaps, e.g., at least the cover portion periphery (which includes the access flaps). In particular embodiments, the WFT may be completely or partially printed, e.g., by a mark or indication, e.g., on the fracture enhancement buttons. In a specific embodiment, the mark or indication printed on each side of the hinge in the WFT prior to closing the container, together, form a unique shape that can be visualized upon closure of the container (i.e., folding of the hinge on the WFT that occurs upon such closure). In a specific embodiment, the WFT may be completely or partially printed upon, while the container regions adjacent to the WFT contain no printing.

In certain embodiments of the present invention, the packaging system comprises an enhanced security locking feature that assists in ensuring structural integrity of the cover portion at one or more sides to prevent the cover from flexing in any manner that would allow access to the contents of the container without removing the WFT. The enhanced security locking feature comprises a male protrusion supporting post centrally located on the inner sidewall of one or more sides of the base portion, e.g., of sufficient size and shape, which is engineered to provide additional support to the cover, and rest within a receiving recess of the cover in the dosed position (e.g., adjacent to the peripheral locking flange assembly). In a specific embodiment, the post is a button engineered to reversibly engage and interlock with the cover portion in the recess located on the cover. In particular embodiments, the cover portion recess located internally adjacent to the peripheral locking flange assembly is modified to receive the male protrusion button, e.g., by flattening the recess location.

In particular embodiments, and without intending to be limiting, such enhanced security locking feature may be present on containers that reach a size where pressing the middle of the cover portion can result in sufficient enough corresponding separation between the upper sealing edge and the peripheral locking flange assembly as to afford unauthorized access to the contents of the container without removing the WFT. In a particular embodiment, only one side of the container possess this enhanced security locking feature. In particular embodiments, two or more sides may possess this enhanced security locking feature.

In certain embodiments of the present invention, the container is comprised of plastic, e.g., clear/see-through or opaque plastic.

In certain embodiments of the invention, the cover portion is designed to be clear for ease of view of the containment area, e.g., PETE.

In another embodiment, the present invention provides a unitary supplementary packaging (USP) system comprising

-   -   an asymmetric truncated rectangular pyramid base portion forming         the primary storage compartment wherein the base portion is         defined by a bottom storage tray in combination with four         containment side-walls enclosing a volume of storage space to         form said primary storage compartment;     -   a cover portion designed to be mated to the rim of the base         portion for opening and closing access into the primary storage         compartment; and     -   a triangular prism shaped supplementary compartment linked to an         extension flange of the base portion through an inversion         support hinge that positions the opening facial angle of the         supplementary compartment adjacent to one containment side-wall         of the base portion, wherein the angle of said one containment         side-wall of the base portion is structured to be a         supplementary pairing angle of the opening facial angle of the         supplementary compartment, and wherein the outside angle of the         supplementary compartment is roughly 90 degrees.

Moreover, in certain embodiments, the unitary supplementary packaging (USP) systems of the present invention may incorporate additional design elements that do not significantly inhibit or prevent the features of the containers explicitly described herein.

A. Cover Portion

The unitary supplementary packaging (USP) systems of the present invention comprise a cover portion designed to be mated to the rim of the base portion for opening and closing access into the primary storage compartment.

In certain embodiments of the present invention, the cover portion further comprises a peripheral locking flange assembly for mating the cover portion and base portion, e.g., wherein the peripheral locking flange assembly comprises a truncated recessed flange (TRF) This peripheral locking flange assembly comprises a flange, i.e., the flange is the outer edge of this assembly, and a locking structure that is designed/constructed to reversibly interlock with the upper peripheral sealing edge of the base portion that is engineered with a negative draft angle, or in-cut, extending substantially about the perimeter of the base portion. The circumferential recess created by this negative draft angle matches the shape of the locking structure of the peripheral locking flange assembly to assist in reversibly securing the cover to the base. In certain embodiments, a chamfer edge design of the cover portion peripheral locking flange assembly affords an ease of closing the cover into a secure interlocked position.

In certain embodiments of the present invention, 1) the cover portion further comprises a peripheral locking flange assembly, and 2) the base portion comprises an upper peripheral sealing edge configured to substantially eliminate access to the peripheral locking flange assembly of the cover portion when the container is in the closed position.

In certain embodiments of the present invention, the peripheral locking flange assembly comprises an outwardly extending peripheral flange.

In certain embodiments of the present invention, the peripheral locking flange assembly comprises a truncated recessed flange (TRF).

In certain embodiments of the invention, the cover portion further comprises a stacking ridge configured to allow a second container to be stacked on top of the unitary supplementary packaging (USP) system.

In certain embodiments of the invention, the cover portion further comprises an optimized surface, e.g., sidewall or top surface, engineered for maximum labeling compatibility.

In certain embodiments of the present invention, the cover portion further comprises printing, e.g., distortion control printed graphics. Distortion control printing, or distortion printing is the process of printing a distorted version of an image onto a sheet of plastic and systematically vacuum forming the sheet on a mold so that specific areas of the printed image appear in intended corresponding areas of the resulting three-dimensional finished product. In particular embodiments, the printed graphics comprise 2 or more colors. In particular embodiments, the printed graphics comprise 3 or more colors. In certain embodiments, the printing may be on the upper surface (product facing) of the container, the lower surface (underside that faces away from the product) of the container, or a combination of both.

In certain embodiments of the invention, the cover portion is comprised of plastic, e.g., clear/see-through or opaque plastic.

In certain embodiments of the invention, the cover portion is designed to be clear for ease of view of the containment area, e.g., PETE.

B. Base Portion

The base portion of the unitary supplementary packaging (USP) systems of the present invention serve as the lower portion of the container, i.e., the portion of the container on which the items stored in the container are placed, and with which the cover portion mates or interlocks. The unitary supplementary packaging (USP) systems of the present invention comprise a base portion that is defined by a bottom storage tray in combination with at least three containment side-walls (e.g., 4 sides) enclosing a volume of storage space to form said primary storage compartment (i.e., wherein such volume is defined by the side walls and bottom storage tray). Further, a small extending flange, the extension flange, is positioned at the outer periphery of the rim of the base portion on the side of the primary compartment that links the primary compartment with the supplementary compartment, and serves to create the proper distance for the inversion hinge to operate. In certain embodiments, the length of the extension flange is equal, e.g., about equal, to the hinge width.

The base portion comprises a rim designed to be mated with the cover portion of the system. This rim comprises an upper peripheral sealing edge, Furthermore, the upper peripheral sealing edge of the base portion is designed/constructed to reversibly interlock with the peripheral locking flange of the cover. The upper peripheral sealing edge of the base portion is engineered with a negative draft angle, or in-cut, extending substantially about the perimeter of the base portion. The circumferential recess created by this negative draft angle matches the shape of the locking structure of the peripheral locking flange assembly to assist in reversibly securing the cover to the base. In certain embodiments, a chamfer edge design of the upper edge of the peripheral sealing edge affords an ease of closing the cover into a secure interlocked position. In certain embodiments, the upper peripheral sealing edge is configured to substantially eliminate access to the peripheral locking flange of the cover portion when the container is in the closed position.

In certain embodiments of the present invention, the base portion shape comprises arced vertices, which create one or more arced edge locks at the corners of the shaped base portion. In particular embodiments, the arced edge lock improves leak resistance when the cover and base portions are interlocked.

In certain embodiments of the invention, the base portion further comprises a return wall engineered to improve structural integrity, e.g., present along the entire outer periphery of the base portion.

In certain embodiments of the invention, the base portion further comprises side ribs, e.g., in the sidewall, engineered to add structural strength and stiffness to the unitary supplementary packaging (USP) system.

In certain embodiments of the invention, the base portion further comprises at least one chamfered corner, e.g., at the bottom perimeter of the base portion, engineered to improve material distribution,

In certain embodiments of the invention, the base portion further comprises side ribs, e.g., in the sidewall, engineered to add structural strength and stiffness to the unitary supplementary packaging (USP) system.

In certain embodiments of the invention, the base portion further comprises printing, e.g., distortion control printed graphics. In particular embodiments, the printed graphics comprise 2 or more colors. In particular embodiments, the printed graphics comprise 3 or more colors. In certain embodiments, the printing may be on the upper surface (product facing) of the container, the lower surface (underside that faces away from the product) of the container, or a combination of both.

In certain embodiments of the invention, the base portion is comprised of plastic, e.g., clear/see-through or opaque plastic.

C. Supplementary Compartment

The unitary supplementary packaging (USP) systems of the present invention comprise a supplementary compartment linked to the base portion through an inversion support hinge that positions the opening facial angle of the supplementary compartment adjacent to one containment side-wall of the base portion, wherein the angle of said one containment side-wall of the base portion is structured to be a supplementary pairing angle of the opening facial angle of the supplementary compartment.

In certain embodiments of the invention, the supplementary compartment comprises a structural ridge positioned adjacent to the inversion support hinge in the facially closed position to facilitate positioning of the opening facial angle of the supplementary compartment against the supplementary pairing angle of said one containment side-wall.

In certain embodiments of the invention, one wall of the supplementary compartment is relatively in the same two dimensional plane as the bottom storage tray of the primary storage compartment.

In certain embodiments of the invention, the supplementary compartment is a triangular prism (see, for example, FIGS. 1-3). In certain embodiments, the outside angle of the supplementary compartment is roughly 90 degrees.

In certain embodiments of the invention, the supplementary compartment is suitable for storing one or more utensils (e.g., a fork, spoon, knife, or any combination thereof).

In certain embodiments of the invention, the supplementary compartment comprises a utensil mount structure (e.g., a mount in which a fork, spoon, knife, or any combination thereof may be placed and held fixed in position)

In certain embodiments of the invention, the unitary supplementary packaging (USP) system further comprising a locking tab assembly for locking the supplementary compartment to the primary storage compartment when the supplementary compartment is positioned in the facially closed position. In certain embodiments, the locking tab assembly comprises a paired button assembly (e.g., with a male button on the supplementary compartment and the paired female button for receiving the male button).

Tamper Evident Linkage Structure

In certain embodiments of the present invention, the systems comprise a tamper evident linkage structure comprising a tamper evident component connecting to the cover and base portions through linking flaps. In certain embodiments, the tamper evident component comprises a wedged fracture tab (WFT), e.g., with an integrated non-frangible hinge. In particular, the WFT of the present invention is engineered as a two layer bi-folded hinged tear tab (as compared to the known single layer tear strips); wherein two sides of a folded hinge are each attached to one of the cover or base portions in a V-shaped wedge through a linking flap. In particular, the WFT comprises two score lines located on each side of the folded hinge, i.e., one closer to the base portion and one closer to the cover portion, configured to allow the fracture of both lines at nearly the same time and the removal of a V-shaped bi-folded wedge; and leaving the linking flaps remaining as access flaps on the cover and base portions that are useful for opening and reopening the container after fracture at the score lines. Such design is a more substantial “break away” feature with reduced risk of damage to the tamper evident component by the person/machine filling the container that can result with known tamper evident components (i.e., prior break way tear strip or tear line designs) due to their structurally weak hinge points between cover and base that are also the point of break away. The bi-folded tab is more easily visualized for evidence of tampering and more easily gripped and torn (or fractured) by the user attempting to open a closed container possessing consumer products. Moreover, in certain embodiments, the WFT is configured to produce access flaps, e.g., alternating linking flaps, upon full fracture and removal of the tab from the cover and base portions of the container.

In certain embodiments of the invention, the wedged fracture tab (WFT) is asymmetrically frangible. In certain embodiments, the asymmetrically frangible wedged fracture tab (WFT) is configured with a contoured frangible score-line. In certain embodiments, the asymmetrically frangible wedged fracture tab (WFT) is configured to produce alternating access flaps upon full fracture and removal of the tab from the cover and base portions of the container. These access flaps are created by the residual of the WFT after the wedged fracture tab has been removed, which produce suitable overlaps or flaps that afford the user repeated access to the contents of the container after the container has been closed and locked, e.g., interlocked.

In one particular embodiment, the alternating access flaps comprise one access flap centered on the base portion between two access flaps located on the cover portion, e.g., as viewed from above. In another particular embodiment, the alternating access flaps comprise one access flap centered on the cover portion between two access flaps located on the base portion, e.g., as viewed from above.

In certain embodiments of the invention, the wedged fracture tab (WFT) further comprises imprinting on the area of the WFT to be removed upon full fracture from the cover and base portions of the container. Alternatively, in certain embodiments of the invention, the access tabs further comprise imprinting, e.g., wherein the imprinting is located on the area of the container that remains upon full fracture and removal of the WFT from the cover and base portions of the container.

In certain embodiments of the present invention, at least one of the access tabs further comprises additional imprints (e.g., for information or grip).

In certain embodiments of the invention, at least one of the access flaps is configured with a grip ridge.

In certain embodiments of the invention, the wedged fracture tab (WFT) further comprises fracture enhancement buttons, e.g., comprising a gripping feature on the tab that enhances the tearing of the WFT. These fracture enhancement buttons afford the user/consumer a greater degree of grip in order to assist in the tearing or fracture of the WFT,

III. Methods of the Invention A. Methods of Preparation

It should be readily understood by the ordinarily skilled artisan in light of the disclosure provided herein that a container constructed in accordance with the present invention can be manufactured in a variety of shapes and sizes, and can be formed from resins or plastic materials such as polyethylene, polypropylene, polyvinyl chloride or polyethyleneterephthalat (“PETE”), as well as other suitable materials or combinations thereof. Moreover, the forming process can also vary to include methods such as thermoforming, injection molding or blow molding. In certain embodiments, the container can be transparent, translucent, or opaque, and may be colored in any instance.

In certain embodiments, and by no means intended to limit the packaging systems of the present invention in terms of design or construction, e.g., material composition, the unitary supplementary packaging (USP) systems of the present invention are prepared by using standard thermoforming techniques/technology, in conjunction with a mold constructed to produce a unitary supplementary packaging (USP) system of the present invention.

In general, thermoforming is a manufacturing process where a plastic sheet is heated to a forming-temperature as to be pliable, formed with a mold into a specific shape, and trimmed to create a usable product. The sheet is heated in an oven to a high-enough temperature that it can be stretched into or onto a mold and cooled to a finished shape. In certain embodiments, the process may be automated, for example, by using large production machines to heat and form the plastic sheet, as well as trim the formed parts from the sheet using a continuous process.

In particular embodiments, plastic sheet may be fed from a roll or from an extruder into a set of indexing chains that incorporate pins, or spikes, which pierce the sheet and transport it through an oven for heating to forming-temperature. The heated sheet then moves through another station, i.e., a form station, where, with the application of vacuum, a mold and pressure-box close on the sheet to produce the desired product, e.g., the unitary supplementary packaging (USP) systems of the present invention. The sheet containing the formed product is then trimmed, e.g., with a die that cuts the product from the remaining sheet web.

In certain embodiments, the molds used in these processes may be comprised of wood, composite, or aluminum.

It should be further understood that part of the thermoform process includes molds that create the score lines or perforations. The ordinarily skilled artisan understand the processes that make these frangible or non-frangible, which are well known in the art.

In certain embodiments of the invention, the unitary supplementary packaging (USP) systems are prepared from a single thermoform plastic sheet.

IV. Design Aspects of the Invention

Independent of the utility related to the packaging systems of the present invention, the ornamental appearance of any novel design provided herein is intended to be part of this invention, for example, each of the perspective views in FIGS. 1 through 3, which may form an independent or combined ornamental appearance of the packaging systems described herein.

Accordingly, one embodiment of the present invention provides an ornamental design for a unitary supplementary packaging (USP) system as shown and described.

Exemplification

Having thus described the invention in general terms, reference will now be made to the accompanying drawings of exemplary embodiments, which are not necessarily drawn to scale, and which are not intended to be limiting in any way.

In this respect, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the Figures. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

FIG. 1 is an exemplary top down perspective view of certain embodiments of the unitary supplementary packaging (USP) systems of the present invention depicted with the cover portion 2 in open position and linked to the base portion through a wedged fracture tab (WFT) hinge 5 to the primary storage compartment 1 wherein the base portion forming the primary storage compartment is defined by a bottom storage tray in combination with at least three containment side-walls enclosing a volume of storage space to form said primary storage compartment. The supplementary compartment 3 is a triangular prism shape and is linked to an extension flange 9 of the base portion 1 through an inversion support hinge 4 that is capable of positioning the opening facial angle of the supplementary compartment 3 adjacent to one containment side-wall 7 of the base portion, wherein the angle of said one containment side-wall of the base portion is structured to be a supplementary pairing angle of the opening facial angle 6 of the supplementary compartment. The male button 8 of the locking tab assembly may be used for locking the supplementary compartment to the primary storage compartment when the supplementary compartment is positioned in the facially closed position when paired with the female recess for receiving the male button that is obstructively shown on the bottom side of the primary compartment 1.

FIG. 2 is the side profile view of certain embodiments of the unitary supplementary packaging (USP) systems of the present invention depicted in FIG. 1, and describe above, Moreover, the unitary supplementary packaging (USP) is depicted from the side perspective with the cover portion 2 in open position and linked to the base portion through a wedged fracture tab (WFT) hinge 5 to the primary storage compartment 1 wherein the base portion forming the primary storage compartment is defined by a bottom storage tray in combination with at least three containment side-walls enclosing a volume of storage space to form said primary storage compartment. The supplementary compartment is a triangular prism shape and is linked to an extension flange of the base portion 1 through an inversion support hinge 4 (more clearly showing a raised ridge on the inversion support hinge) that is capable of positioning the opening facial angle of the supplementary compartment 3 adjacent to one containment side-wall 7 of the base portion, wherein the angle of said one containment side-wall of the base portion is structured to be a supplementary pairing angle of the opening facial angle 6 of the supplementary compartment. The male button 8 of the locking tab assembly may be used for locking the supplementary compartment to the primary storage compartment when the supplementary compartment is positioned in the facially closed position when paired with the female recess for receiving the male button that is obstructively shown on the bottom side of the primary compartment 1. Further, the outer angle 10 is clearly depicted by a curved arrow.

FIG. 3 is another top down perspective view of certain embodiments of the unitary supplementary packaging (USP) systems of the present invention depicted with indications of the frangible and non-frangible score lines. Score lines 13 and 14 of the wedged fracture tab (WFT) hinge are perforated tear lines to facilitate tearing; where the score line 12 is a non-frangible hinge line affording bending/flexing without risk of breaking. Score lines 15 and 17 are non-frangible hinge lines affording bending/flexing of the inversion support hinge from the primary compartment and the supplementary compartment. Score line 11 is a non-frangible hinge line affording bending/flexing of the male button of the locking tab assembly. Further, the extension flange 9 is highlighted, along with the structural ridge 16 on the supplementary compartment positioned adjacent to the inversion support hinge to facilitate positioning of the opening facial angle of the supplementary compartment against the supplementary pairing angle of said one containment side-wall.

INCORPORATION BY REFERENCE

The entire contents of all patents, published patent applications and other references cited herein are hereby expressly incorporated herein in their entireties by reference.

Equivalents

Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents were considered to be within the scope of this invention and are covered by the following claims. Moreover, any numerical or alphabetical ranges provided herein are intended to include both the upper and lower value of those ranges. In addition, any listing or grouping is intended, at least in one embodiment, to represent a shorthand or convenient manner of listing independent embodiments; as such, each member of the list should be considered a separate embodiment. 

What is claimed is:
 1. A unitary supplementary packaging (USP) system comprising a base portion forming the primary storage compartment wherein the base portion is defined by a bottom storage tray in combination with at least three containment side-walls enclosing a volume of storage space to form said primary storage compartment; a cover portion designed to be mated to the rim of the base portion for opening and closing access into the primary storage compartment; and a supplementary compartment linked to an extension flange of the base portion through an inversion support hinge that positions the opening facial angle of the supplementary compartment adjacent to one containment side-wall of the base portion, wherein the angle of said one containment side-wall of the base portion is structured to be a supplementary pairing angle of the opening facial angle of the supplementary compartment.
 2. The unitary supplementary packaging (USP) system of claim 1, wherein the inversion support hinge is connected to the extension flange of the base through a flexible non-frangible score line.
 3. The unitary supplementary packaging (USP) system of claim 1, wherein the inversion support hinge is connected to the flange of the supplementary compartment through a flexible non-frangible score line.
 4. The unitary supplementary packaging (USP) system of claim 1, wherein the width of the inversion support hinge is about the same as the base extension flange length.
 5. The unitary supplementary packaging (USP) system of claim 1, wherein the inversion support hinge comprises a raised ridge.
 6. The unitary supplementary packaging (USP) system of claim 1, wherein the supplementary compartment comprises a structural ridge positioned adjacent to the inversion support hinge in the facially closed position to facilitate positioning of the opening facial angle of the supplementary compartment against the supplementary pairing angle of said one containment side-wall.
 7. The unitary supplementary packaging (USP) system of any one claims 1 to 6, wherein one wall of the supplementary compartment is relatively in the same two dimensional plane as the bottom storage tray of the primary storage compartment.
 8. The unitary supplementary packaging (USP) system of claim 7, wherein the supplementary compartment is a triangular prism.
 9. The unitary supplementary packaging (USP) system of claim 8, wherein the outside angle of the supplementary compartment is roughly 90 degrees.
 10. The unitary supplementary packaging (USP) system of any one of claim 7, 8 or 9, wherein the system may be positioned in a standing orientation on the outside wall and rim of the base portion creating a consumer favorable display angle of the primary storage compartment.
 11. The unitary supplementary packaging (USP) system of claim 1, wherein the supplementary compartment is suitable for storing one or more utensils.
 12. The unitary supplementary packaging (USP) system of claim 1, wherein the supplementary compartment comprises a utensil mount structure.
 13. The unitary supplementary packaging (USP) system of claim 1, further comprising a locking tab assembly for locking the supplementary compartment to the primary storage compartment when the supplementary compartment is positioned in the facially closed position.
 14. The unitary supplementary packaging (USP) system of claim 13, wherein the locking tab assembly comprises a paired button assembly.
 15. The unitary supplementary packaging (USP) system of claim 1, wherein the cover portion further comprises a peripheral locking flange assembly for mating the cover portion and base portion, and wherein the peripheral locking flange assembly comprises a truncated recessed flange (TRF).
 16. The unitary supplementary packaging (USP) system of claim 1, further comprising a hinge connecting the cover portion to the base portion.
 17. The unitary supplementary packaging (USP) system of claim 16, wherein the hinge is positioned opposite the inversion support hinge.
 18. The unitary supplementary packaging (USP) system of claim 21, wherein the hinge comprises a tamper evident linkage structure.
 19. The unitary supplementary packaging (USP) system of claim 18, wherein the tamper evident linkage structure comprises a wedged fracture tab (WFT) wherein the WFT is configured to produce access flaps upon full fracture and removal of the tab from the cover and base portions.
 20. The unitary supplementary packaging (USP) system of claim 19, wherein the asymmetrically frangible wedged fracture tab (WFT) is configured to produce alternating access flaps upon full fracture and removal of the tab from the cover and base portions of the container. 